Vehicle trim part having a layered, decorative finish and configured to form a light pattern at the front of the part

ABSTRACT

A vehicle trim part having a layered, decorative finish is provided. The part includes a polymeric substrate, a decorative layer overlying the polymeric substrate and a light-transmissive, protective layer overlying and protecting the decorative layer. The protective layer includes a front surface and a rear surface having a surface portion with a translucent surface finish. The decorative layer has an opening extending from a rear surface of the decorative layer to a front surface of the decorative layer and aligned with the translucent surface finish. Both a cross section of the opening at the front surface of the decorative layer and the translucent surface finish are sized and shaped to form a light pattern which is visible at the front of the part when artificial lighting illuminates the translucent surface finish from the rear of the part.

TECHNICAL FIELD

This invention generally relates to vehicle trim parts and, inparticular, to such parts which are configured to form a light patternat the front of the parts.

OVERVIEW

Interior lighting systems for automotive and other vehicle applicationsare generally used for two purposes. One is to provide general areaillumination and the other is feature lighting of specific objects,either for aesthetic or functional reasons. Traditionally, theseinterior lighting systems have utilized incandescent lamps for both areaand feature lighting, often using lenses to control the shape and lightintensity distribution of the emitted light. Although incandescent lampsystems can often be integrated into various vehicle interior trimcomponents in a simple manner, various considerations do arise whichcomplicate their use for automotive lighting. For example, where heatfrom the lamp could damage adjacent components or otherwise causeproblems, thermal management of that heat must be implemented. Also,there is often little room in or behind a particular vehicle interiorbody panel or trim component for the lamp, socket, and lensing.

More recently, distributed light systems have found use in vehicles.These may use fiber optics or other means to deliver the light to adesired location. The use of a lens and focusing or dispersing devicesmay be employed to direct the light.

Such areas as foot wells, door handles, seats, trunks, cargo areas,dashboards, door sills, headliners, grab handles, etc. may beilluminated using a wide combination of technologies. In addition toincandescent lights and fluorescent lighting, LED illumination, coldcathode technology, and electroluminescent technology may now find use.

Vehicles are commonly provided with various types of decorative trimparts. Vehicles also typically have various logos or designs located oninterior trim pieces. However, decorative trim and designs in thevehicle cabin are difficult to perceive in darker conditions. Attemptshave been made to illuminate trim logos. This is typically done byeither placing the logo within the field of a light source or by makingthe logo element luminescent. The first method is not feasible for logosin most common locations, while the latter method may adversely affectthe occupants' vision.

Some plastic automotive parts are covered with wood trim after they aremolded. Sometimes such plastic parts are composite plastic parts whereinan outer layer of the part is in-molded with a structural substrate ofthe part.

One practice in the automotive industry is utilization of all-plastic,fabricated parts, such as, but not limited to, instrument panels,interior trims, and door panels. It is known in other automotive partsareas that different, aesthetically pleasing outer surfaces enhance theoverall appearance of the interior of automotive vehicles. Use ofdecorative appliques having wood grain finishes is often sought after.

Wood grain finishes are typically in the form of either simulated woodgrain or genuine wood grain. The simulated wood grain finish may beachieved in one of several known manners: 1) backing a pre-printed filmby a thin layer of a thermoplastic, such as polycarbonate; ABS(acrylonitrile/butadiene/styrene), or aluminum, followed byvacuum-forming to obtain the desired shape of the trim; 2) applying alithograph on an aluminum sheet; and 3) dipping a substrate into acontainer of ink defining the wood grain appearance. Simulated woodgrain finishes, however, are generally not as attractive as genuine woodgrain finishes.

Genuine wood grain finishes may also be obtained in one of several knownmanners: 1) staining, sealing and protecting preformed laminates of woodhaving varying thicknesses which are then attached to a substrate viastapling, gluing, or any other similar attachment manner; 2) laminatingan aluminum sheet with the genuine wood which is then welded or screwedonto a plastic part; and 3) adhesively bonding a thin laminate of woodto a pre-processed plastic substrate which is then stained and coveredwith a protective top-coat. Although the appearance of genuine wood ismore attractive than simulated wood, the use of genuine wood is moreexpensive than that of simulated wood.

Compression molding is a method of molding in which the moldingmaterial, generally preheated, is first placed in an open, heated moldcavity. The mold is closed with a top force or plug member, pressure isapplied to force the material into contact with all mold areas, whileheat and pressure are maintained until the molding material has cured.The process may employ thermosetting resins in a partially cured stage,either in the form of granules, putty-like masses, or preforms.Compression molding is a high-volume, high-pressure method suitable formolding complex, high-strength fiberglass reinforcements. Advancedcomposite thermoplastics can also be compression molded withunidirectional tapes, woven fabrics, randomly oriented fiber mat orchopped strand. The advantage of compression molding is its ability tomold large, fairly intricate parts. Also, it is one of the lowest costmolding methods compared with other methods such as transfer molding andinjection molding; moreover it wastes relatively little material, givingit an advantage when working with expensive compounds.

The following U.S. patent documents are related to the presentinvention: U.S. Pat. Nos. 5,895,115; 6,158,867; 6,193,399; 6,464,381;6,594,417; 6,652,128; 6,974,238; 7,150,550; 7,201,588; 7,237,933;7,299,892; 7,387,397; 7,987,030; 8,016,465; 8,075,173; 8,162,519;8,215,810; 8,235,567; 8,256,945; 8,408,627; 8,408,766; 8,425,062;8,449,161; 8,469,562; 8,596,803; and 8,627,586; and U.S. PublishedApplications 2009/0251917; 2011/0002138; 2012/0188779; 2012/0217767;2013/0279188; and 2014/0077531.

Despite the teachings of the above U.S. patent documents, there is stilla need for an easily and inexpensively manufactured vehicle trim parthaving a decorative, layered finish and configured to form a lightpattern at the front of the part such as a logo or image.

SUMMARY OF EXAMPLE EMBODIMENTS

An object of at least one embodiment of the present invention is toprovide a vehicle trim part having a layered, decorative finish andconfigured to form a light pattern at the front of the part and whereinthe part can be easily and inexpensively manufactured.

In carrying out the above object and other objects of at least oneembodiment of the present invention, a vehicle trim part including apolymeric substrate, a decorative layer overlying the polymericsubstrate and a light-transmissive, protective layer overlying andprotecting the decorative layer is provided. The protective layerincludes a front surface and a rear surface having a surface portionwith a translucent surface finish. The decorative layer has an openingextending from a rear surface of the decorative layer to a front surfaceof the decorative layer and aligned with the translucent surface finish.Both a cross section of the opening at the front surface of thedecorative layer and the translucent surface finish are sized and shapedto form a light pattern which is visible at the front of the part whenartificial lighting illuminates the translucent surface finish from therear of the part.

A light pattern may be visible at the front of the part when naturallighting illuminates the translucent surface finish from the front ofthe part.

The protective layer may comprise a clear top coat layer.

The substrate may have an opening which extends from the rear surface ofthe substrate to a front surface of the substrate and which is alignedwith the translucent surface finish and the opening in the decorativelayer.

The decorative layer may be in contact with the substrate.

The protective layer may be in contact with the decorative layer.

The decorative layer may be in contact with the substrate and theprotective layer.

The part may be an interior trim part.

The light pattern may be an image such as a graphic image.

The light pattern may be a logo.

The protective layer may be transparent.

The surface portion of the rear surface of the protective layer may bemachined under controlled conditions to form the translucent surfacefinish.

The surface portion of the rear surface of the protective layer may beetched or blasted with a blasting material to form the translucentsurface finish.

The front surface of the protective layer may be a class A frontsurface.

The decorative finish may be a wood grain finish.

The decorative layer may be opaque.

Further in carrying out the above object and other objects of at leastone embodiment of the present invention, a vehicle trim part having alayered, decorative finish is provided. The part includes a polymericsubstrate, a decorative layer overlying the polymeric substrate and alight-transmissive, protective layer overlying and protecting thedecorative layer. The protective layer includes a front surface and arear surface having a plurality of separate surface portions. Each ofthe surface portions has a translucent surface finish. The decorativelayer has openings which extend from a rear surface of the decorativelayer to a front surface of the decorative layer. Each of the openingsis aligned with one of the translucent surface finishes. Cross sectionsof the openings at the front surface of the decorative layer and theircorresponding translucent surface finishes are sized and shaped to formlight patterns which are visible at the front of the part whenartificial lighting illuminates the translucent surface finishes fromthe rear of the part.

Still further in carrying out the above object and other objects of atleast one embodiment of the present invention, an illuminated vehicletrim part having a layered, decorative finish is provided. The partincludes a polymeric substrate, a decorative layer overlying thepolymeric substrate and a light-transmissive, protective layer overlyingand protecting the decorative layer. The protective layer includes afront surface and a rear surface having a surface portion with atranslucent surface finish. The decorative layer has an openingextending from a rear surface of the decorative layer to a front surfaceof the decorative layer and aligned with the translucent surface finish.The part also includes a source of illumination for emitting rays oflight and disposed at the rear of the part so that the light rays fallon the translucent surface finish. The source is configured to beelectrically coupled to an electrical system of the vehicle. Both across section of the opening at the front surface of the decorativelayer and the translucent surface finish are sized and shaped to form alight pattern which is visible at the front of the part when the sourceof illumination illuminates the translucent surface finish with thelight rays from the rear of the part.

Yet still further in carrying out the above object and other objects ofat least one embodiment of the present invention, an illuminated vehicletrim part having a layered, decorative finish is provided. The partincludes a polymeric substrate, a decorative layer overlying thepolymeric substrate and a light-transmissive, protective layer overlyingand protecting the decorative layer. The protective layer includes afront surface and a rear surface having a plurality of separate surfaceportions. Each of the surface portions has a translucent surface finish.The decorative layer has openings which extend from a rear surface ofthe decorative layer to a front surface of the decorative layer. Each ofthe openings is aligned with one of the translucent surface finishes.The part also includes at least one source of illumination for emittingrays of light and disposed at the rear of the part so that the lightrays fall on the translucent surface finish. Each source is configuredto be electrically coupled to an electrical system of the vehicle. Crosssections of the openings at the front surface of the decorative layerand their corresponding translucent surface finishes are sized andshaped to form light patterns which are visible at the front of the partwhen the at least one source of illumination illuminates the translucentsurface finishes with the light rays from the rear of the part.

Other technical advantages will be readily apparent to one skilled inthe art from the following figures, descriptions and claims. Moreover,while specific advantages have been enumerated, various embodiments mayinclude all, some or none of the enumerated advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an environmental view, partially broken away, of the interiorof passenger vehicle having vehicle trim part constructed in accordancewith at last one embodiment of the present invention;

FIG. 2A is a front elevational view, partially broken away, of thevehicle trim part of FIG. 1 wherein the word “logo” is visible vianatural, ambient light;

FIG. 2B is a view similar to the view of FIG. 2A, but with a “logo”light pattern visible via artificial light located at the rear of thepart;

FIG. 3 is a view, partially broken away and in cross section, takenalong lines 3-3 of FIG. 2A and schematically illustrating a process totexture a pair of spaced surface portions on the back surface of aprotective layer to form translucent surface finishes;

FIG. 4 is an enlarged view of a circled portion of FIG. 3 to show one ofthe textured surfaces and further including artificial lighting to forma light pattern at the front of the part; and

FIG. 5 is a schematic sectional view illustrating various apparatus formaking and using the illuminated vehicle trim part constructed inaccordance with at least one embodiment of the present invention.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

As used in this application, the term “substrate” refers to anyflexible, semi-flexible or rigid single or multi-layer component havinga surface to which a decorative layer or coating is or can be applied bythe methods described herein such as, without limitation, polymers andother plastics, as well as composite materials. Furthermore, the shapeof the substrate and particularly the surface to be coated or layeredcan be any part of an assembly or device manufactured by any of variousmethods, such as, without limitation, conventional molding, extruding,or otherwise fabricated. One preferred application contemplated hereinis the coating of substrates that are automotive components such asautomotive interior trim components.

The term “overlies” and cognate terms such as “overlying” and the like,when referring to the relationship of one or a first, superjacent layerrelative to another or a second, subjacent layer, means that the firstlayer partially or completely lies over the second layer. The first,superjacent layer overlying the second, subjacent layer may or may notbe in contact with the subjacent layer; one or more additional layersmay be positioned between respective first and second, or superjacentand subjacent, layers.

Referring now to FIG. 1, a motor vehicle, generally indicated at 10, maybe equipped with a vehicle trim panel or part, generally indicated at12, constructed in accordance with at least one embodiment of thepresent invention. While the part 12 is shown as an interior trim part12, the trim part could be an exterior trim part.

As shown in FIG. 5, the part 12 may be electrically connected to acontroller 14 which, in turn, is electrically connected or coupled to anelectrical system 16 of the vehicle 10. The panel 12 is backlit and maybe selectively turned “on” and “off” by the controller 14 whichcontrollably supplies electrical power from the system 16 to the panel12. The controller 14 is typically electrically connected to one or moreswitches and/or one or more sensors so that the panel 12 can be manuallyor automatically operated to turn the panel 12 “on” or “off”. Forexample, the controller 14 can be electrically connected to an ignitionswitch, a light sensor, a headlight switch and/or an interior lightswitch as needed and/or desired.

FIG. 2A shows the trim part 12 when not illuminated by artificial lightat the rear of the part (i.e. not backlit). Rather, the part 12 isilluminated by ambient, natural lighting at the front of the part 12.FIG. 2B shows the trim part or panel 12 when illuminated by artificiallight via side or back artificial lighting.

FIGS. 3 and 4 show the multiple layers of the part 12, including apolymeric substrate, generally indicated at 20, a decorative layer,generally indicated at 22, overlying the substrate 20 and alight-transmissive protective layer, generally indicated at 24,overlying and protecting the decorative layer 22. A source ofillumination, generally indicated at 26, disposed at the rear of thepart 12 converts the part 12 into an illuminated vehicle trim part. Thesource of illumination 26 may be coupled or connected to the substrate20 or may be spaced away from the substrate 20 and supported by adifferent part of the vehicle 10.

The decorative layer 22 may comprise one of a decorative film, a foil, alaminate, a veneer, a fabric, paper or a coating. For example, thedecorative layer 22 may comprise a coverstock sheet bonded to thesubstrate by press molding in a mold such as a mold, generally indicatedat 30 in FIG. 5. The coverstock sheet may provide the trim panel 12 witha wood grain finish. The coverstock sheet may include a natural woodlayer. The wood grain finish of each coverstock sheet may be simulated.The coverstock sheet may use a textured, real-wood surface appearance.The coverstock sheet may include a synthetic resin layer. The coverstocksheet may include a simulated real-wood layer. After the press orcompression molding, a varnish or stain coating may be placed on theouter surface.

The protective layer 24 may be a clear top coat layer as overlying andprotecting the decorative layer. The layer 24 may be a transparent ortranslucent plastic such as polycarbonate, acrylic, ABS, plexi-glass,lexant; polypropylene, poly(methyl methacrylate), thermoplasticurethane, polyester, copolyester alloy, cyclic olefin copolymer,poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allylester, styrene-acrylonitrile, polystyrene, polyvinyl chloride andblends, alloys and combinations thereof. The layer 24 may include one ormore pigments, tints, colored dyes, metallic flakes or light reflectiveparticles therein. The layer 22 and/or the layer 24 may include one ormore anti-fading components, one or more anti-soiling components and oneor more water-repellant compounds.

The protective layer 24 includes a front surface 32 and a rear surface34 having a one or more surface portions 36 with a translucent surfacefinish 36 which causes light to be dispersively transmitted through thelayer 24. The surface finish 36 typically hides or conceals anyartificial lighting apparatus or equipment located at the rear of thepart 10 during either “on” or “off” conditions.

The decorative layer 22 has an opening 40 extending from a rear surface42 of the decorative layer 22 to a front surface 44 of the decorativelayer 22 and aligned with the translucent surface finish 36.

The substrate 22 also has an opening 50 which extends from a rearsurface 52 of the substrate 22 to the front surface 54 of the substrate22 and aligned with the translucent surface finish 36 and the opening 40in the decorative layer 22. Both the opening 40 and the opening 50 mayhave a reflective layer (not shown) to reflect light rays from thesource of illumination 26 towards the translucent surface finish 36.

The openings 40 and 50 may be machined through the layer 20 and thesubstrate 22, respectively, by a CNC machine 60 as shown in FIG. 5 aftermolding of the unfinished part in the mold 30. The sizes and shapes ofthe openings 40 and 50 are typically input into the machine 60 at aninput 62 such as a graphical user interface for the machine 60. Afterthe openings 40 and 50 are formed, the CNC machine 60 may machine, suchas by grinding and/or polishing, portions 36 of the rear surface 34 ofthe layer 24 to form the translucent surface finish(es). Alternatively,the translucent surface finishes 36 may be formed by shot or sandblasting, acid or laser etching, or water pressure.

As described above, the unfinished part is typically molded without anylogo or image as shown in FIG. 5. Then the logo or image is machinedfrom the back side of the part at a predetermined depth into the part.The resulting pattern is visible by itself and also can be illuminatedas previously described.

The source of illumination 26 may include an incandescent bulb, afluorescent bulb, a light emitting diode (LED), a light pipe, anelectroluminescent device, a neon or argon bulb or fiber optics. Thelight source(s) may produce light of any color or from any portion ofthe light spectrum. In various exemplary embodiments, a light filter(not shown) may be placed between the light source and the portions 36of the rear surface 34. Also, the light source(s) may be included on orin the part 12 or spaced away from the part.

Both a cross section of the opening 40 at the front surface 44 of thedecorative layer 22 and the translucent surface finish 36 are sized andshaped to form one or more light patterns which are visible at the frontof the part 12 when artificial lighting illuminates the translucentsurface finish from the rear of the part 12 as shown in FIG. 2B.

The one or more light patterns are visible at the front of the part 12when natural lighting illuminates the translucent surface finish 36 fromthe front of the part 12 as is shown in FIG. 2A. The one or more lightpatterns may be one or more images such as one or more graphic images.The one or more light patterns may be a logo as shown in FIGS. 2A and2B.

In summary, the part 12 is provided with a feature for lighting to showa logo or image at the front of the part 12. The lighted logo or imagecan be seen as an A-surface of the part. The image or logo can be viewedduring the day and is illuminated at night.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. A vehicle trim part having a layered, decorativefinish, the part comprising: a polymeric substrate; a decorative layeroverlying the polymeric substrate; and a light-transmissive, protectivelayer overlying and protecting the decorative layer, the protectivelayer including a front surface and a rear surface having a surfaceportion with a translucent surface finish, the decorative layer havingan opening extending from a rear surface of the decorative layer to afront surface of the decorative layer and aligned with the translucentsurface finish, wherein both a cross section of the opening at the frontsurface of the decorative layer and the translucent surface finish aresized and shaped to form a light pattern which is visible at the frontof the part when artificial lighting illuminates the translucent surfacefinish from the rear of the part.
 2. The part as claimed in claim 1,wherein the light pattern is visible at the front of the part whennatural lighting illuminates the translucent surface finish from thefront of the part.
 3. The part as claimed in claim 1, wherein theprotective layer comprises a clear top coat layer.
 4. The part asclaimed in claim 1, wherein the substrate has an opening extending fromthe rear surface of the substrate to a front surface of the substrateand aligned with the translucent surface finish and the opening in thedecorative layer.
 5. The part as claimed in claim 1, wherein thedecorative layer is in contact with the substrate.
 6. The part asclaimed in claim 1, wherein the protective layer is in contact with thedecorative layer.
 7. The part as claimed in claim 1, wherein thedecorative layer is in contact with the substrate and the protectivelayer.
 8. The part as claimed in claim 1, wherein the part is aninterior trim part.
 9. The part as claimed in claim 1, wherein the lightpattern is an image.
 10. The part as claimed in claim 9, wherein theimage is a graphic image.
 11. The part as claimed in claim 1, whereinthe light pattern is a logo.
 12. The part as claimed in claim 1, whereinthe protective layer is transparent.
 13. The part as claimed in claim 1,wherein the surface portion of the rear surface of the protective layeris machined under controlled conditions to form the translucent surfacefinish.
 14. The part as claimed in claim 1, wherein the surface portionof the rear surface of the protective layer is etched or blasted with ablasting material to form the translucent surface finish.
 15. The partas claimed in claim 1, wherein the front surface of the protective layeris a class A front surface.
 16. The part as claimed in claim 1, whereinthe decorative finish is a wood grain finish.
 17. The part as claimed inclaim 1, wherein the decorative layer is opaque.
 18. A vehicle trim parthaving a layered, decorative finish, the part comprising: a polymericsubstrate; a decorative layer overlying the polymeric substrate; and alight-transmissive, protective layer overlying and protecting thedecorative layer, the protective layer including a front surface and arear surface having a plurality of separate surface portions, each ofthe surface portions having a translucent surface finish, the decorativelayer having openings which extend from a rear surface of the decorativelayer to a front surface of the decorative layer, each of the openingsbeing aligned with one of the translucent surface finishes, whereincross sections of the openings at the front surface of the decorativelayer and their corresponding translucent surface finishes are sized andshaped to form light patterns which are visible at the front of the partwhen artificial lighting illuminates the translucent surface finishesfrom the rear of the part.
 19. An illuminated vehicle trim part having alayered, decorative finish, the part comprising: a polymeric substrate;a decorative layer overlying the polymeric substrate; alight-transmissive, protective layer overlying and protecting thedecorative layer, the protective layer including a front surface and arear surface having a surface portion with a translucent surface finish,the decorative layer having an opening extending from a rear surface ofthe decorative layer to a front surface of the decorative layer andaligned with the translucent surface finish; and a source ofillumination for emitting rays of light and disposed at the rear of thepart so that the light rays fall on the translucent surface finish, thesource being configured to be electrically coupled to an electricalsystem of the vehicle and wherein both a cross section of the opening atthe front surface of the decorative layer and the translucent surfacefinish are sized and shaped to form a light pattern which is visible atthe front of the part when the source of illumination illuminates thetranslucent surface finish with the light rays from the rear of thepart.
 20. An illuminated vehicle trim part having a layered, decorativefinish, the part comprising: a polymeric substrate; a decorative layeroverlying the polymeric substrate; a light-transmissive, protectivelayer overlying and protecting the decorative layer, the protectivelayer including a front surface and a rear surface having a plurality ofseparate surface portions, each of the surface portions having atranslucent surface finish, the decorative layer having openings whichextend from a rear surface of the decorative layer to a front surface ofthe decorative layer, each of the openings being aligned with one of thetranslucent surface finishes; and at least one source of illuminationfor emitting rays of light and disposed at the rear of the part so thatthe light rays fall on the translucent surface finish, each source beingconfigured to be electrically coupled to an electrical system of thevehicle and wherein cross sections of the openings at the front surfaceof the decorative layer and their corresponding translucent surfacefinishes are sized and shaped to form light patterns which are visibleat the front of the part when the at least one source of illuminationilluminates the translucent surface finishes with the light rays fromthe rear of the part.